CN1177121C - Laminate roof flashing material - Google Patents

Abstract

A pliable, ductile plate-shaped roof flashing is disclosed. The roof flashing has a laminate structure comprising a composite layer and a foil sheeting on one or both sides of the composite layer. The composite layer comprises a carrier material and one or more non-structural constituents. At least one of the non-structural constituents comprises a heavy metal compound having a density higher that 3.5 g/ml.

Description

Laminate roof flashing material

technical field

The present invention relates to a sheet roof flashing of flexible, ductile laminate construction comprising a composite layer and sheet metal applied to one or both sides of the composite layer.

Background technique

Flashing material in the form of panel members or skirts is used to make sealed connections between building structures penetrating the roof surface, for example between the main frame of a roof-mounted window and the surrounding roofing material, especially As a skirt flashing at the lower horizontal member of the main frame.

Such material is traditionally a lead sheet about 1 mm thick. Lead has many advantages as a flashing material because it is easily deformed plastically and has limited elasticity, that is, the lead sheet substantially retains its original bent shape without any elastic springback. This inherent property of lead is of great advantage when the lead skirting is formed as part of a fixed flashing directly on, for example, a corrugated roof surface, in which case to compensate for possible elastic springback , the skirt must not be excessively bent.

Although lead has little elasticity in most applications, there is still minimal springback, but because lead is a heavy material, gravity alone will cause the lead skirting to flex elastically into tight contact with the roof surface. Furthermore, the high density and corresponding high weight of the lead also prevents the skirt from buckling back during stormy weather.

Indeed, lead also has some well-known disadvantages, since it is harmful to the environment, expensive to transport and handle due to its weight, and difficult to work with, for example when joining different lead components together. In addition, the lead oxidizes, leaving streaky deposits on the surrounding roof surface.

In order to avoid the economic and environmental problems caused by the traditional use of lead as the flashing material, it is suggested that the flashing should be made of a sandwich structure, which typically consists of a central layer of tough material that suppresses and stabilizes stress on one side. Cover with a thin layer. Typically the center layer is made of a polymeric or bituminous product and the sheet material is a thin metal sheet, preferably aluminum sheet. Bitumen as a product grade is usually tacky at ambient temperatures to ensure adhesion and stability to the sheet metal, but when using a non-tacky center layer material it must be coated with a pressure sensitive Adhesive coating. Such flashing materials are disclosed in, for example, Danish patent specification 148064 and No. 145509, and German patent specification DE-A-4 032 058.

In order to be applied on the roof surface of corrugated tiles with deep troughs, the above-mentioned corrugated sandwich structure has been further developed into a corrugated and pleated structure in order to obtain sufficient artificial deformability and stretchability, so as to prevent There is a good fit between the rainboard and the roof.

Even with these improved constructions, however, it has been difficult to obtain a tight and durable fit between the flashing and the roof.

Thereby sandwich-type flashings have been proposed in which another layer or another structure is embedded or added to the central layer, such as the embedded metal fiber mesh disclosed in GB-A-2 184 685 or WO 95/31620 or Grids, embedded polymer grid structures in DE-U-298 04 503, or additional metal sheets in WO 99/13180. But these structures greatly increase the manufacturing cost, and also bring problems, that is, when the metal fiber material of the metal fiber mesh is crushed during installation and then penetrates the material it is embedded in and the covering metal sheet, which allows water to enter inside the house.

GB-A-1 095 393 discloses an adhesive laminate that can be used, for example, to provide a water and dust seal for building connections. The laminate includes a self-adhesive bituminous composition applied to a flexible protective layer. The bituminous composition may contain filler materials, preferably fibrous and powdery fillers. The proposed filler material in powder form is ground wollastonite and calcium carbonate surface treated with stearic acid.

Lead-free flashing materials proposed in the prior art have struggled to gain a foothold in the market as a competitive and equivalent alternative to lead flashing. Instead of trying to improve conventional lead flashing by employing a pleated or folded structure in which the thickness of the lead layer has been reduced, efforts have been made to provide the weather resistance of lead flashing by painting or painting.

Contents of the invention

Therefore, noting the above, it is an object of the present invention to provide an improved flashing material which has one or more of the above-mentioned favorable characteristics of lead flashing, namely, easy bending, while having very limited elastic deformation, It has a high density and is moreover easy and cheap to manufacture.

Disclosure of the invention

Accordingly, the present invention relates to a material for flexible, ductile plank roof flashing, which has a laminated structure comprising a composite layer and metal sheets laid on one or both sides of the composite layer, wherein The composite layer includes a support material and one or more non-structural components, at least one of which includes heavy metal compounds with a density higher than 3.5 g/ml.

The roof flashing having a composite layer of support material and at least one additional non-structural component has some or more of the similar characteristics of lead as described above.

By the term "non-structural" it is meant a component that does not itself constitute a rigid sheet or plate-like structure, as in the case of the fibrous web or lattice structures described above. The non-structural components are not dispersed in the support material as separate hosts. By "heavy metal compound" it is meant a compound having a density greater than 3.5 g/ml and including heavy metals. The heavy metal compound preferably has a density above 4.5 g/ml, a heavy metal being an element in the periodic table having a density above 3 g/ml.

In the first aspect of the present invention, the composite layer includes one or more non-structural components, the non-structural components are composed of heavy metal compounds with a density higher than 3.5 g/ml, so that the density of the composite layer material is higher than that of the support material, However, like the support material, plastic deformation can occur. By "support material" it is meant a composite material that requires less than 5 times, preferably less than 2 times the force required to set the shape of the support material.

The nonstructural components, including heavy metal compounds, are usually present as dispersed solid particles in the support matrix. The shape of the solid particles varies widely, but the average diameter of the particles is usually less than 2 times, preferably less than 5 times the thickness of the composite layer. The particles consisting of heavy metal compounds are preferably uniformly distributed in the support matrix so that the overall performance of the flashing is the same. In order to obtain a high density of this nonstructural component, it is preferable to use metal particles consisting of pure metals or alloys thereof. But some heavy metals, like iron, are prone to oxidation when exposed to normal weather conditions if the heavy metal layer is not adequately protected within the supporting matrix. It is therefore preferable to use non-structural components in which the heavy metal compound is bound in a compound. In addition, heavy metals bound in a compound, such as an inorganic salt, are generally less expensive than pure heavy metals or their alloys.

The non-structural component is usually based on an organic or inorganic material of the mineral, ceramic, metallic or polymeric type and includes an amount of metal either as metallic particles or as metal bound in a compound. Examples of suitable heavy metals are barium, iron, silver, molybdenum and copper. The heavy metal compound is preferably an inorganic salt or an oxide of the aforementioned heavy metal. Examples of suitable salts are chlorides, sulfates, sulfides, or nitrates of the abovementioned metals. A preferred heavy metal compound is barium sulfate because of its ease of repair and low cost. In general, non-structural components that are durable are preferable to those that degrade easily. If the protective film is damaged, it is crucial that the non-structural components are not degraded by weather, such as acid rain. Barium sulfate meets this requirement, while calcium carbonate, which is not suitable as a heavy metal compound, will be dissolved by acid rain.

Other heavy metal-free compounds can also be used as particulate material. As an example, it is advantageous to include carbon black in the composite composition.

In a second aspect of the invention, the composite layer comprises one or more non-structural components which form a composite layer material which is less elastic than the support material but which deforms substantially the same as the support material. By composite ply material it is meant a composite material that requires less than 5 times the force required for a given deformation, preferably less than 2 times that force.

The term "elasticity" refers to the relative elongation that can occur before plastic deformation occurs, in the sense that low elasticity means that only small relative elongation/deformation can occur before plastic deformation occurs.

The aforementioned plastic deformability is achieved by including in the composite layer material an additional non-structural component consisting of fibrous material.

In a preferred embodiment, the additional components are based on organic or inorganic non-rigid mesh sheets, or non-structural fibrous materials, preferably composed of fibers, fine fibers, rovings, etc., which are based on mineral, ceramic, metal or polymeric components or constituents or compounds thereof. Suitable examples of fibrous materials are asbestos, rock wool, and amphibole fibers. Preferred embodiments have a fine fiber length of less than 10 cm, preferably less than 5 cm, most preferably less than 1 cm. It is best to align the fine fibers in the main direction for good directional stability.

The content of non-structural components in the support matrix can vary depending on the intended use of the flashing. Nonstructural material contents of up to 95% by weight in the composite layer material have been found. In order for the composite ply material to be of sufficient weight, preferably more than 50% of the composite ply material consists of non-structural materials. If more than 75% by weight of the composite layer material is composed of non-structural components, a relatively flexible and tough flashing can be obtained. The preferred density of the composite layer is 2 g/ml or more, more preferably 2.5 g/ml or more. Usually the thickness of the roof flashing composite layer is 0.5-5mm, and the best thickness is 0.7-2mm.

In preferred embodiments, the non-structural components used interact with and isolate the structure of the support material such that the resulting composite ply material is less elastic than the support material, yet plastically deforms substantially the same.

Presently, the preferred support materials are polymeric materials, such as PVC, or butyl rubber (styrene-butadiene radial block copolymer), and asphalt products. Bitumen is preferred for some aspects of the invention because it is viscous enough at ambient temperature to bond to sheet metal. Butyl rubber is often preferred when environmental concerns are an important consideration. But the viscosity of butyl rubber (and PVC) is usually not sufficient for producing durable laminates with metal sheets. It is therefore necessary and desirable to use adhesives for lamination.

As noted above, the composite core material of the present invention may be used in flashings having two or more layers, ie, laminate or sandwich structures. According to the invention, the composite material is covered on one or both sides with sheets of eg mineral, ceramic, metallic or polymeric type. Accordingly, the sheet is a metal sheet, preferably an aluminum sheet. The sheet can be pleated. In addition, the sheet is covered with a varnish for decorative purposes or to increase the service life of the roof flashing.

Advantageously, the sheet has a thickness in the range of 0.1-0.5 mm.

When the composite is covered with a sheet on one side only, the other side may be covered with a release pellicle. The membrane is torn off before the flashing is used. If the composite layer is tacky or if the composite layer is coated with an adhesive, the roof flashing will stick to the building structure for a tight bond.

The adhesive used to secure the non-adhesive or insufficiently adhesive composite layer to the sheet or release film may be of any suitable type that provides an adhesive of sufficient strength. In some aspects of the invention, it may be advantageous to use double sided tape as an additional layer between the composite layer and the veneer or the pellicle.

It is advantageous to apply a friction reducer on the interface of the composite ply with the sheet. Suitable examples of friction reducers are graphite and molybdenum sulfide.

The flashing can be corrugated in one or two directions in order to improve the overall stretchability, for example in order to make the roof surface corrugated tiles with deep troughs.

The roof flashing of the present invention can be fabricated following conventional lamination techniques. As an example of a suitable manufacturing process for the roof flashing of the present invention, the following process may be guided.

Firstly, a liquid composite material containing support material and non-structural components is prepared. Support materials that can be used are generally solid at normal ambient temperatures. Therefore, the support material is heated at least until the viscosity of the molten support material is low enough that it can be stirred. The nonstructuring components are then added to the liquid support material and dispersed in the support material by agitation. Stirring is preferably continued until the nonstructural components have been uniformly distributed in the support material.

The liquid composite material containing the dispersed non-structural component is applied to a sheet, usually aluminum sheet, at the desired thickness. Sometimes a second sheet can be attached to the free side of the composite ply to obtain a three-ply laminate. Next, the composite ply material is hardened by cooling to a suitable temperature.

An alternative to this process is to make the composite layer separately and then laminate the sheets on one and both sides. If the composite layer material is viscous at normal temperature or slightly higher temperature, a composite layer or a composite layer can be prepared by casting a liquid composite material and then hardened by cooling. The adhesive composite layer is laminated to the veneer in a separate process. When the composite layer covers the sheet only on one side, it can be covered with a release film on the other side. The release membrane is torn off before the roof flashing is used.

If the composite material is non-adhesive another process is used which is suitable for applying an adhesive between the composite ply and the veneer.

It is necessary to treat the laminate with a suitable friction reducer between the veneer and the composite ply in order to ensure that the structure does not delaminate when stresses are applied to the finished roof flashing. Examples of suitable friction reducers are _MoS2 and graphite.

Detailed description of the drawings

The present invention is described in detail with reference to accompanying drawing now, and among the accompanying drawings:

Figure 1 shows a perspective view of a roof flashing.

Example: Preparation of Roof Flashing in Laminate Structure

A strip of composite material is prepared. First melt 14kg of butyl rubber (styrene-butadiene radial block copolymer). While stirring the molten polymer, 1 kg of carbon black and 85 kg of granular barium sulfate were added. When the carbon black and barium sulfate had been distributed uniformly in the liquid butyl rubber, a strip was cast. The tape solidified upon cooling to ambient temperature and the resulting composite had a density of 2.7 g/ml and was highly cohesive.

Obtain a strip of aluminum sheet twice the width of the composite strip. The aluminum sheet is bent around one side of the composite tape in a lamination unit and adhesive is applied to the interface between the aluminum sheet and the composite tape to obtain a 5-ply roof flashing.

In the embodiment shown in the drawings, the roof flashing comprises a rail member 10 and a skirt member 20, the rail member is fixed to the skirt along an edge of the skirt and mounted on the skirt and for example The main frames of the windows of a pitched roof act as connectors. The rail member includes many parts, such as 11, 12, 13, 14, 15, which are used as windows and/or roof connectors. Since they are of little relevance to the understanding of the present invention, they will not be further described.

The apron 20 is shown in a partial cross-sectional view, from which it can be seen that it includes a five-layer laminated structure: an upper cover layer 21 , a top middle layer 22 , a center layer 23 , a lower middle layer 24 and a lower cover layer 25 .

The upper and lower cover layers 21 , 25 are aluminum sheets which have been secured to the composite layer 23 by means of adhesive layers 22 , 24 . If the composite layer itself is sufficiently viscous, i.e., there is sufficient adhesion between the upper and lower cover layers, that the center layer is not considered necessary, the intermediate layer may be omitted, especially if the cover layer is bent around the free edge 26 of the center layer It can be saved when single thin sheet.

In the illustrated embodiment, the skirt is corrugated in the direction of its free edge.

As also indicated in the opening part of this application, the skirting layer is the main element of the flashing in terms of ensuring a proper fit, stable and reliable sealed connection between the fenestration element and the roof. To ensure compliance with these requirements, it is ideal to ensure ease of assembly of the apron, which ensures that the apron fits securely and tightly against the roof and stays in place regardless of time or external influences. For this reason, the composite material of the present invention is easy to bend artificially, relatively heavy in weight, and less elastic.

Claims (19)

1. A kind of flexible, tenacity plank roof rainproof board of laminated structure, this laminated product comprises a composite layer and the thin plate that spreads on this composite layer one or both sides, it is characterized in that: composite layer comprises a A support material and one or more non-structural components, at least one of which is present in the composite layer in the form of particles and includes heavy metal compounds with a density greater than 3.5 g/ml. 2. The roof flashing according to claim 1, characterized in that the density of the heavy metal compound is 4.5 g/ml or above. 3. Roof flashing according to claim 1 or 2, characterized in that the non-structural constituent comprises heavy metal compounds in the form of metal particles. 4. The roof flashing of claim 1, wherein the non-structural component comprises a heavy metal compound as a metal bound in the compound. 5. The roof flashing according to claim 4, wherein the heavy metal in the non-structural compound is selected from barium, iron, silver, and copper. 6. The roof flashing of claim 5, wherein the non-structural component is barium sulfate. 7. The roof flashing of claim 1, wherein the composite ply material present as the other non-structural component comprises fibrous material. 8. The roof flashing of claim 7, wherein the fiber length of the non-structural material is less than 10 cm. 9. The roof flashing of claim 7, wherein the fiber length of the non-structural material is less than 5 cm. 10. The roof flashing of claim 7, wherein the fiber length of the non-structural material is less than 1 cm. 11. Roof flashing according to any one of claims 7-10, characterized in that the fibers are aligned in the main direction. 12. The roof flashing of claim 1 wherein the non-structural material constitutes 95% by weight of the composite layer. 13. The roof flashing of claim 1, wherein the non-structural material constitutes more than 50% by weight of the composite ply material. 14. The roof flashing of claim 1, wherein the non-structural material constitutes more than 75% by weight of the composite ply material. 15. The roof flashing according to claim 1, characterized in that the sheet is a thin metal sheet with a thickness in the range of 0.1-0.5mm. 16. The roof flashing of claim 15, wherein the sheet metal is aluminium. 17. The roof flashing plate according to claim 1, characterized in that the density of the composite layer material is 2.5g/ml or above. 18. The roof flashing of claim 1, wherein the sheet-like roof flashing is corrugated. 19. The roof flashing of claim 1, wherein the sheet includes pleats.